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INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 43

Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 164 of 303

8.7.8.2 Automatic sensing of the fuel level in the loco tank should be done through the

ultrasonic fuel level sensor fitted in the loco.

8.7.8.3 Depending on the fuel level in the loco tank and level required to be maintained,

calculation should be done by the console and accordingly fuelling pump started
and cut off, after completion of the filling of the required amount of fuel.

8.7.8.4 The fuelling pumps should have facility of remote on an off for facilitating

automatic fuelling in the locos.

8.7.8.5 Storage tanks should have the facility of automatic measurement of fuel level,

accordingly it can be decided as to from which storage tank how much fuelling
can be done. The level so recorded should also be periodically relayed to a
central server for record and viewing by the division and HQ officials.

8.7.8.6 Fuel meters should also have the facility of automatic relaying of the amount of

fuel filled up in the locos.

8.7.8.7 The amount of fuel filled in the loco and other details should be automatically

relayed to the central server for record and viewing by various divisional and
HQ officials.

8.8

Periodicity of Maintenance of RCD installation: Summary of periodicity of
maintenance of various parts of RCD is as under:-

Activity

Frequency

Cleaning of Storage
Tanks

Every 5 years (4
years, if need be)

Para 3.4 of Rly. Board’s JPO of
Feb’10

Painting of Storage tanks Every 5 years (4

years, if need be)

Para 3.4 of Rly. Board’s JPO of
Feb’10

Changing of Flowmeters

15 years after
installation

dispensing of 4
lakh kl, whichever
is earlier.

Para 5.3 of Rly. Board’s JPO of
Feb’10

Calibration of
flowmeters

Once in a year by
Oil company

Para 5.3 of Rly. Board’s JPO of
Feb’10

Joint Inspection with Oil
Firms’s representative

Once in a Quarter

As per agreement between the
Railways and Oil Firms

8.9

Security and Safety of RCDs:

8.9.1

RCD holds precious and inflammable commodity. Hence, it is very important that
proper security at each RCD is provided. As per Standing Order No. 88 of Rly.
Board, communicated vide letter no.2003/Sec/(E)/PO-2/5 dt 13th May 2009, RPF
should provide security at RCDs, as it falls under core activity (it does specifically
state so but since it has not been mentioned as one of the non-core areas, it is
inferred that it is core activity). But, later on this Standing order has been held in
abeyance by Board. Nonetheless, Railways to ensure that security at RCDs is
provided at the earliest.

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Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 165 of 303

8.9.2

In terms of Railway Board’s letter No. 2009/Fuel/282/19 dt. 30/11/2009 all
Railways should ensure that a current valid clearance of the Chief Controller of
Explosives, Nagpur is obtained for every RCD duly meeting all conditions and a
copy is kept in the RCDs, without fail.

8.9.3

The inherent danger of fire around a diesel fuelling installation is due to the
formation of inflammable vapours resulting from the leakage or spillage of oil. Fire
prevention measures must, therefore, curtail oil leakage and avoid practices which
may allow vapours to form or collect. The possibilities of ignition can be minimized
by ensuring that the equipment is in good condition and that the operating
instructions are worked to properly. Proper fire fighting facilities should be
available so that in case of a fire breaking out, it is possible to combat it.

8.9.4

The following will help to minimize oil leakage and spillage and, thus, safeguard
against fire hazards:

a. Welded pipe joints in fuel lines reduce oil leakage.

b. Air vents should terminate in open atmosphere outside the pump house.

c. Pressure relief valves should be piped back into the storage system and not

discharged to atmosphere.

d. Fuel pumps should be equipped with proper seals to safeguard against fuel oil

leakages.

e. Areas around fuel installations should be paved so that if any oil is spilled, it is

possible to clean it easily. Concrete paved platform with proper slope to provide
quick drainage into sumps or drains is recommended.

f. Naked lights should never be brought near the tanks even when they are empty.

Oil rags and waste easily catch fire and therefore should not be allowed to
accumulate near the fuel installation area.

8.9.5

Exposure to extremes of temperatures would result in evaporation and loss of fuel,
besides involving risk of fire. Leakage also has the same harmful effects. Tanks
containing fuels should, wherever possible, be shaded from direct sun light
otherwise wide temperature variations will increase the chances of water
condensation within the tanks. When fuel becomes hot, it expands and forces some
of the air above it to go out of the tank. On cooling, the air and water vapour are
drawn into the tank resulting in water contamination of fuel.

8.9.6

In terms of Railway Board’s Lr.No.2009/Fuel/282/19 Dt. 09-11-2009 Railways
should ensure following fire fighting facilities at fuelling installations :

Items

Major installation

Medium

Installation

Minor

Installation

DCP fire
extinguishers- 70 Kg

4 nos. around
storage tank

4 nos. around
pump room
Generator Room

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Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 166 of 303

Items

Major installation

Medium

Installation

Minor

Installation

DCP fire
extinguishers- 10 Kg

8 nos. around
pump room
Generator Room

DCP fire
extinguishers- 5 Kg

1 No. at each
fuelling point

CO2 fire
extinguishers- 5 Kg

3 Nos. for tackling
computer and
electrical fires

2 Nos. for tackling
computer and
electrical fires

1 No. for tackling
computer and
electrical fires

Sand Buckets

8 Nos.

4 Nos.

Hand Operated Siren
(dynamically
balanced) with range
of 1.5 Kms

8.9.7

Proper mechanism of maintenance of the above-mentioned fire fighting facilities
should be in place in each RCD.

Procedure for Accountal of Diesel Fuel

8.10 Indenting

8.10.1

Each Railway will work out a time table so that the indent is prepared and
submitted in time.

8.10.2

Division/Diesel Shed should work out the requirements of HSD oil for the RCDs in
their jurisdiction. These should take into account anticipated variation in the train
operation during the next financial year. Arrangement for new/additional storage
capacity (normally being 15 days consumption plus lead time) / pumping should be
reviewed and specific proposals along with the requirements of next financial year
sent to fuel branch. Fuel branch will forward the requirement of HSD oil and
new/additional storage capacity along with details of direct demanding officers to
Controller of Stores for procurement. In case of placement of rate/running
contracts, COS will advise fuel branch of the Railway and all Divisions/Diesel
Sheds and RCDs in-charges.

For rate contracts, supply orders shall be placed by COS. For running contracts
direct demanding officers will place orders on suppliers. A fresh order should be
placed when balance quantity due on a supply order is reduced to two months
consumption.

Fuel branch should control and regulate day to day supply of HSD oil by tank
wagons or by RTTs. A close watch on the trend of consumption vis-à-vis
rate/running contract should be kept and amendments called for through COS, as
and when necessary.

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Document No:

Chapter –8 Fuel & Lubricants

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 167 of 303

8.11 Loading advice and Railway receipt:

8.11.1

Loading advices should be sent by suppliers by postal dak within 24 hours of
loading to the consignee. These should be serially numbered for each consignee
separately and should contain the following particulars for each loading day :

a.  Tank wagon number/lorry number
b.  Carrying capacity
c.  Net quantity loaded in liters
d.  Date of loading
e.  Loading station code

Copies of the loading advice will be simultaneously dispatched by postal dak to the
FA&CAO and fuel branch

8.11.2

The RR should be sent to consignee immediately by the supplier to enable the
former to take delivery.

8.11.3

The supplier will prepare a statement in Form No.1 in respect of each bill and send
two copies to consignee and one copy to FA&CAO. The form should be serially
numbered for each consignee and this serial number should be indicated in the bills
sent for payment.

8.12 Pocket Card Labels and Tie-on-labels:

8.12.1

It shall be the responsibility of the base stations to provide pocket card-labels and
tie-on-labels on both sides of tank wagons showing:

a.  Tank wagon No.
b.  Full booking particulars.
c.  Supplier’s name
d.  Consignee’s name and station booked to
e.  Quantity loaded in litres as per RR at temperature ------

C and dip

measurement in cm.

In a case of short receipt, these should be preserved until the cases have been resolved.

8.13 Receipt and Accountal in the RCDs:

8.13.1

On arrival of HSD Tank wagon(s) at the destination, the same will be received by
the official-in-charge of the RCD and in case there is any evidence of the seals
having been disturbed/ tampered with, the delivery should be effected in the
presence of the traffic and RPF representative (if posted), Dip measurements taken
and damage deficiencies message, if found, issued in accordance with the IRCA
rules in vogue. Whenever shortages are found, these will be recorded in Form No.2
and should be pursued with the Commercial Branch through FA&CAO (Stores).
The provision of section 76C of Indian Railways Act for delivery of goods at
sidings will also be applicable.

8.13.2

For short receipts detected in seals intact tank wagons booked under “Said to
Contain” RRs covered by modified transit risk clause, claims for the cost of HSD
oil received short with proportionate freight charges should invariably be advised to
the Company within 30 days of the receipt of the tank wagons. A copy of this claim
should be endorsed to the CCM (Claims) with the request that if supplying oil
Company does not issue credit notes for the claims preferred within 15 days of
preferring the claims, the same should be recovered from supplying oil Company’s
subsequent bills by FA&CAO (Stores).

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